Foundry flask

ABSTRACT

A foundry flask includes at least three discrete corner sections and at least three discrete side sections wherein the yield strength of the corner sections is greater than the yield strength of the side sections. Each one of the corner sections is connected to a pair of the side sections so as to form a foundry flask section that has at least three sides. The foundry flask further includes a bottom member that is connected to the foundry flask section.

BACKGROUND

[0001] The invention pertains to a foundry flask. The invention also pertains to a foundry flask section that when used with a bottom section forms a foundry flask. The invention still further pertains to a corner section for use with side sections wherein the assembly of the corner sections and the side sections forms a foundry flask section.

[0002] Heretofore, a foundry flask comprised a bottom member that was connected to a foundry flask section. Between the bottom member and the foundry flask section there was defined a volume that contained sand. Prior to the formation of the casting cavity, the sand contained a pattern that defined the shape of the casting cavity. After formation of the casting, the sand contained the cast part.

[0003] In these earlier foundry flasks, the entire structure of the foundry flask section was made from the same material. More specifically, in some cases the entire foundry flask section was made from a cast material that exhibited high tensile strength and yield strength along the entire circumference of the section. While these higher strengths were desirable, the cost of such a foundry section was prohibitive, especially when the need for the higher strengths along the sides of the foundry section was not necessary.

[0004] In other cases, the entire foundry section was made from a wrought material that presented a lower tensile strength and lower yield strength along the entire circumference of the flask. The lower cost of the wrought foundry section was a desirable aspect. However, while these lower strengths were adequate for the sides of the flask, they were not desirable for the corners of the flask since the foundry flask was lifted at the corners during the movement thereof.

[0005] Until now there has not been a foundry flask that utilizes the performance advantages of cast material for the corner sections along with the cost advantages of wrought material for the side sections. The present invention provides a foundry flask with the performance advantages of cast material for the corner sections and the cost advantages of wrought material for the side sections. Furthermore, the cast corner sections themselves provide for cast-in integral projections that facilitate lifting the foundry flask. These integral projections also facilitate flipping the foundry flask by providing the necessary points of connection to permit a change in the center of gravity and momentum needed to flip the foundry flask.

[0006] Heretofore, earlier foundry flasks have not had the ability to easily adapt their dimensions to a specific application. However, in light of the fact that the wrought material for the side sections can be cut to length, the present invention also provides for the ability to customize the size of the foundry flask, as well as the foundry flask section height to fit a specific application. What this means is that the present invention provides for the modular construction of foundry flask sections.

SUMMARY

[0007] In one form thereof, the invention is a foundry flask that includes at least three discrete corner sections and at least three discrete side sections. Each one of the corner sections is connected to a pair of the side sections so as to form a foundry flask section having at least three sides. The foundry flask further includes a bottom member that is connected to the foundry flask section.

[0008] In still another form thereof, the invention is a foundry flask that comprises at least three discrete corner sections wherein each one of the corner sections has a first tensile strength. The foundry flask further comprises at least three discrete side sections, each one of the side sections that each have a second tensile strength. The first tensile strength is greater than the second tensile strength. Each one of the corner sections is connected to a pair of the side sections wherein the corner section is mediate of the pair of the side sections. The corner sections and the side sections when connected together form a foundry flask section. There is a bottom section that is connected to the foundry flask section.

[0009] In yet another form thereof, the invention is a foundry flask section for use with a bottom member to form a foundry flask. The foundry flask section comprises at least three discrete corner sections wherein each one of the corner sections has a first tensile strength and a first yield strength. The foundry flask section further comprises at least three discrete side sections wherein each one of the side sections has a second tensile strength and a second yield strength. The first tensile strength is greater than the second tensile strength and the first yield strength is greater than the second yield strength. Each one of the corner sections is connected to a pair of the side sections wherein the corner section is mediate of the pair of the side sections.

[0010] In another form thereof, the invention is a corner section for use with one or more discrete side sections and a bottom section in a foundry flask wherein the corner section cooperates with a lifting member to move the foundry flask. The cast corner section comprises a body that has a mediate portion and a pair of distal portions integral with the mediate portion wherein each distal portion extends away from the mediate portion. The mediate portion and the integral distal portions define an interior surface of the body and an exterior surface of the body. The exterior surface of the body contains a channel. An integral projection projects from the exterior surface of the body.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The following is a brief description of the drawings that form a part of this patent application:

[0012]FIG. 1 is an isometric view of one specific embodiment of a foundry flask that comprises four foundry flask sections wherein the lower foundry flask section has a bottom member affixed thereto, and wherein the foundry flask contains sand and a cast part therein;

[0013]FIG. 2 is an isometric view of the lower foundry flask section from FIG. 1 with portions of the bottom member and the foundry flask section broken away in several locations, and having a chain selectively engaging the projections on the cast corner sections;

[0014]FIG. 3 is an isometric view of a cast corner section from the specific embodiment of FIG. 2 showing the interior surface of the corner section;

[0015]FIG. 4 is an isometric view of the cast corner section of FIG. 3 showing a portion of the exterior surface;

[0016]FIG. 5 is an isometric view of the cast corner section of FIG. 3 having the wrought side section connected to the cast corner section, and showing another portion of the exterior surface;

[0017]FIG. 6 is an isometric view of one of the distal ends of the cast corner section of FIG. 3;

[0018]FIG. 7 is an isometric view of a specific embodiment of a four-sided foundry flask including two vertically stacked foundry flask sections and having the foundry flask sections and the bottom member broken away in several locations;

[0019]FIG. 8 is an isometric view of another specific embodiment of foundry flask wherein the foundry flask is of a hexagonal shape and includes a foundry flask section and a bottom member;

[0020]FIG. 9 is an isometric view of a cast corner section from the foundry flask of FIG. 8 showing the top surface and one portion of the exterior surface thereof; and

[0021]FIG. 10 is an isometric view of the cast corner section of FIG. 9 showing the top surface and another portion of the exterior surface thereof.

DETAILED DESCRIPTION

[0022] Referring to the drawings, there is shown in FIG. 1 a foundry flask generally designated as 20. The foundry flask 20 comprises an upper foundry flask section 22 and a lower foundry flask section 24. The upper foundry flask section 22 and the lower foundry flask section 24 are joined together by a pair of foundry flask sections 25A and 25B to form a foundry flask. A description of the structural details of the foundry flask sections is set forth below. As shown in FIG. 1, the foundry flask 20 contains a sand mold 28 with a cast part 29 therein.

[0023] Referring to FIG. 2, there is illustrated the lower foundry flask section generally designated as 24 with a bottom member 34 affixed thereto. The bottom member 34 is generally rectangular in shape. The lower foundry flask section 24 includes four cast corner sections 36, and four wrought elongate side sections 38. In the drawing (FIG. 2.), the wrought section 38 and the bottom member 34 are broken away at several locations. This is indicative that the length of the side sections 38 and the dimensions of the bottom member 34 can be made to accommodate any specific casting application.

[0024] Preferably, each one of the cast corner sections 36 is made from a 4130 modified material with a tensile strength of 105,000 pounds per square inch (psi) and a yield strength of 85,000 psi. Preferably, each one of the wrought side sections 38 is made from A36 material with a tensile strength of 58,000 psi and a yield strength of 38,000 psi.

[0025] As can be appreciated, the material from which each cast corner section 36 is made is different from the material out of which is made each wrought side section 38. In view of the higher loads experienced by the cast corner section 36, the cast corner section 36 must possess a higher tensile strength and a higher yield strength than that of the wrought side section 38. In this regard, it is preferable that the cast corner section has a minimum tensile strength of 105,000 psi and a minimum yield strength of 85,000 psi.

[0026] The wrought side sections 38 do not experience loads that require them be made from a material that possess the higher tensile strengths and higher yield strengths such as required by the cast corner section 36. In this regard, it is preferable that the wrought side section has a minimum tensile strength of 58,000 psi and a minimum yield strength of 38,000 psi.

[0027] Referring to FIG. 2 through 6, each one of the cast corner sections 36 has a central portion 42. The central portion 42 has an exterior surface 44 that contains a channel 46 therein. The cast corner section 36 further contains an aperture 48 therein. The aperture 48 can be used in conjunction with a projection to lock the flask sections in place during movement thereof. Each one of the cast corner sections 36 also has one integral arm portion 54 that has a top smooth sliding surface 56 and a bottom smooth sliding surface 58. The one integral arm portion 54 further has an abutment or shoulder 60 at the juncture of the one integral arm portion 54 and the central portion 42. There is a volume 62 in the one integral arm portion 54.

[0028] Each one of the cast corner sections 36 also has another integral arm portion 64 that has a top smooth sliding surface 66 and a bottom smooth sliding surface 68. The other integral arm portion 64 further has an abutment (or shoulder) 70 at the juncture of the other integral arm portion 64 and the central portion 42. There is a projection 72 that projects away from the exterior surface. The projection 72 has a reduced diameter section 74 and an enlarged diameter section 76. There is a volume 78 in the other integral arm portion 64.

[0029] Referring to FIG. 5, each one of the wrought side sections 38 has a mediate portion 86 and a pair of opposite arms 88 and 90. Arms 88 and 90 each extend at an angle of about 90 degrees with respect to the surface of the mediate portion 86.

[0030] Referring to the assembly of the assembly of the cast corner sections 36 and the wrought side sections 38, the opposite distal end of each wrought side section 38 essentially slides on and over the integral arm portions (54, 64) of the cast corner section 36. The interior surface of each one of the arms (88, 90) of the side section 38 slides on the top sliding surface 66 and bottom sliding surface 68, respectively. The side section 38 is moved toward the central portion 42 of the cast corner section 36 until the distal end abuts against the abutment 70. Once in the correct position, the side section 38 may be welded or bolted or affixed in another fashion to the cast corner section 36.

[0031] This assembly technique is used to connect both arm portions of each one of the four cast corner sections 36 to the four wrought side sections 38 so as to form a four-sided foundry section. The bottom member 34 is affixed to the bottom edges of the four cast corner sections and the four wrought side sections so as to form the lower foundry flask section.

[0032] The upper foundry flask section 22 comprises four cast corner sections 36 and four wrought side sections 38 assembled together as described above. The upper foundry flask section 22 does not have a bottom member so that it is open at its top and bottom.

[0033]FIG. 2 shows that there is a chain 94 that passes over the projection 72 of alternate cast corner sections 36. The chain 94 also passes under the projection 72 of the remaining cast corner sections 36. It is through the use of the chain 94 (as connected to an overhead crane or the like) that the foundry flask can be flipped over. In this regard, the projection from each one of the cast corner sections provides appoint to facilitate lifting the foundry flask and also provide the necessary points of connection to permit a change in the center of gravity and momentum needed to flip the foundry flask.

[0034] As shown in FIG. 7., there is shown another arrangement of a foundry flask that has upper and lower foundry flask sections (22 and 24, respectively). Each foundry flask section (22 and 24) has four cast corner sections 36 and four elongate wrought side sections 38. The materials for cast corner sections 36 and the wrought side sections 38 are the same as those for the embodiment of FIG. 1.

[0035] As shown in FIGS. 8 through 10, there is another specific embodiment of a foundry flask generally designated as 96. Foundry flask 96 is generally hexagonal in shape. Foundry flask 96 contains six cast corner sections 100 and six wrought side sections 101.

[0036] Each one of the cast corner sections 100 has a central portion 102. The central portion 102 has an exterior surface 104 that contains a channel 106 therein. The cast corner section 100 further contains an aperture 108.

[0037] Each one of the cast corner sections 100 also has one integral arm portion 114 that has a top surface 116 and a bottom surface 118. The one integral arm portion 114 further has an abutment or shoulder 120 at the juncture of the one integral arm portion 114 and the central portion 102. There is a volume 122 in the one integral arm portion 54.

[0038] Each one of the cast corner sections 100 also has another integral arm portion 128 that has a top surface 130 and a bottom surface 132. The other integral arm portion 128 further has an abutment or shoulder 134 at the juncture of the other integral arm portion 128 and the central portion 102.

[0039] A projection 136 projects away from the exterior surface. The projection 136 has a hook 138. There is a volume 140 in the other integral arm portion 128.

[0040] Each one of the wrought side sections 101 has a mediate portion 142 and a pair of opposite arms 144.

[0041] Referring to the assembly of the assembly of the cast corner sections 100 and the wrought side sections 101, the opposite distal end of each side section essentially slides over the integral arm portions (114, 128) of the cast corner section 100. The interior surface of each one of the arms of the side section 101 slides on its corresponding top sliding surface and bottom sliding surface. The side section is moved toward the central portion of the cast corner section until the distal end abuts against the abutment. This assembly technique is used to connect the six cast corner sections to the six wrought side sections so as to form a hexagonal foundry flask section

[0042] It is clear that the specific embodiments each describe a foundry flask that comprises at least three discrete corner sections and at least three discrete side sections. In one specific embodiment there are four discrete corner sections and four side sections. In another specific embodiment there are six discrete corner sections and six discrete side sections.

[0043] The specific embodiments each also show that each one of the corner sections is connected to a pair of the side sections so as to form a foundry flask section that has at least three sides. A bottom member is connected to the foundry flask section. The bottom member and the foundry flask section define there between a volume that contains sand and a casting cavity (that may contain molten or solidified metal) that is surrounded by the sand. One specific embodiment also shows that each one of the corner sections includes a channel and an outwardly projecting projection wherein the channel and the projection cooperate with a lifting member (e.g., a chain that passes through the channel) to move the foundry flask (or facilitate flipping the foundry flask).

[0044] The specific embodiments each also disclose that each one of the discrete corner sections has a first tensile strength and a first yield strength and each one of the discrete side sections has a second tensile strength and a second yield strength. The first tensile strength is greater than the second tensile strength and the first yield strength is greater than the second yield strength. The first yield strength is great enough so as to engage the lifting member without failure when the foundry flask is filled with sand and a cast part.

[0045] The patents, patent applications, and other documents identified herein are hereby incorporated by reference herein.

[0046] Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification of the practice of the invention disclosed herein. It is intended that the specification and examples be considered as illustrative only, and that the true spirit and scope of the invention being indicated by the following claims. 

What is claimed is:
 1. A foundry flask comprising: at least three discrete corner sections; at least three discrete side sections; each one of the corner sections being connected to a pair of the side sections so as to form a foundry flask section having at least three sides; and a bottom member connected to the foundry flask section.
 2. The foundry flask according to claim 1 wherein the bottom member and the foundry flask section define there between a volume, the volume containing sand and a pattern surrounded by the sand.
 3. The foundry flask according to claim 2 wherein each one of the corner sections including a channel and an outwardly projecting projection wherein the channel and the projection cooperate with a lifting member to move the foundry flask.
 4. The foundry flask according to claim 3 wherein the lifting member comprises a chain that passes through the channel and engages the projection so as to facilitate flipping of the foundry flask.
 5. The foundry flask according to claim 1 wherein the bottom member and the foundry flask section define there between a volume, the volume containing sand, and the sand defining a casting cavity therein.
 6. The foundry flask according to claim 1 wherein each one of the corner sections comprising a material that has a minimum tensile strength of about 105,000 psi and a minimum yield strength of about 85,000 psi.
 7. The foundry flask according to claim 1 wherein each one of the side sections comprising a material that has a minimum tensile strength of about 58,000 psi and a minimum yield strength of about 38,000 psi.
 8. The foundry flask according to claim 1 comprising at least four of the discrete corner sections and at least four of the side sections.
 9. The foundry flask according to claim 1 comprising at least six of the discrete corner sections and at least six of the discrete side sections.
 10. A foundry flask comprising: at least three discrete corner sections, each one of the corner sections having a first tensile strength; at least three discrete side sections, each one of the side sections having a second tensile strength, and the first tensile strength being greater than the second tensile strength; each one of the corner sections being connected to a pair of the side sections wherein the corner section is mediate of the pair of the side sections, the corner sections and the side sections when connected together form a foundry flask section; and a bottom section connected to the foundry flask section.
 11. The foundry flask according to claim 10 wherein each one of the corner sections having a first yield strength and each one of the side sections having a second yield strength, and the first yield strength being greater than the second yield strength.
 12. The foundry flask according to claim 11 wherein the bottom member and the foundry flask section define there between a volume, the volume containing sand, and the sand defining a casting cavity therein.
 13. The foundry flask according to claim 12 wherein the casting cavity being filled with metal.
 14. The foundry flask according to claim 13 wherein each one of the corner sections including a channel and an outwardly projecting projection wherein the channel and the projection cooperate with a lifting member to move the foundry flask.
 15. The foundry flask according to claim 14 wherein the yield strength of the corner section is great enough so as to engage the lifting member without failure.
 16. A foundry flask section for use with a bottom member to form a foundry flask, the foundry flask section comprising: at least three discrete corner sections, each one of the corner sections having a first tensile strength and a first yield strength; at least three discrete side sections, each one of the side sections having a second tensile strength and a second yield strength, and the first tensile strength being greater than the second tensile strength, and the first yield strength being greater than the second yield strength; each one of the corner sections being connected to a pair of the side sections wherein the corner section is mediate of the pair of the side sections.
 17. The foundry flask section according to claim 16 wherein each one of the corner sections including a channel and an outwardly projecting projection wherein the channel and the projection cooperate with a lifting member to move the foundry flask when filled with sand and a cast part, and the first yield strength of the corner section being great enough so as to engage the lifting member without failure.
 18. A corner section for use with one or more discrete side sections and a bottom section in a foundry flask wherein the corner section cooperates with a lifting member to move the foundry flask, the cast corner section comprising: a body having a mediate portion, and a pair of distal portions integral with the mediate portion, and wherein each distal portion extends away from the mediate portion; the mediate portion and the integral distal portions defining an interior surface of the body and an exterior surface of the body; the exterior surface of the body containing a channel; and an integral projection projecting from the exterior surface of the body. 